Plastic framed laminated panel and method



E. WINER June25,

PLASTIC FRAMED LAMINATED PANEL AND METHOD Filed Sept. 15, 1942 EPHen/MWIA/sz,

l Km2; Wfrfm @www Patented June 25, 1.946

Pms'rrc FRAMED LAMINA'rr-:D PANEL AND METHOD Ephraim Winer, Baltimore,Md., assigner to The National Plastic Products Company, Odenton,

Md., a corporation of Maryland Application September 15, 1942, SerialNo. 458,477

. 8 Claims. l This invention relates to framed panels and the method ofmaking same. and more particularly to laminated panels such as backed upglass mirrors protected and sealed along their perimeters or marginswith channel-like frame means which may comprise an extruded plastic.Prior to the instant invention it has been customary to mount mirrors inframes in a manner similar to the framing of a picture. When suchconventional framing is desired, the frame section is generallyL-shaped, so that one leg of the L covers the face of the mirror, andthe other leg of the L covers the edge of the mirror. A backing such aswood may then generally be placed loosely on the back of the mirror andwithin the leg of the frame which covers the edge of the mirror. If theframe is of wood nails may be partially driven into the frame to holdthe wood backing in place thereby holding the mirror within the frame inthe generally accepted manner that a picture is held within a frame.Such mountings may be acceptable for some uses such as, for example,where a purely decorative effect is desired.

If such a conventionally mounted mirror is to have lasting qualities,great care must be taken with the back or mirrored surface of the glass.It has been customary, for example, to plate the mirrored surface of theglass with copper to protect the mirrored surface. This plating stepincreases the costof the mirror and while it affords some additionalprotection under static conditions, it has been found to beunsatisfactory for many uses unless additional protective means areutilized. Such prior mirrors are generally unsatisfactory for use inbathrooms, for example, because the edges are unsealed permitting theentrance of dirt, steam, condensation and moisture. Furthermore, if themirror forms a door to a cabinet this prior construction isunsatisfactory because conditions are` not static and the mirror mustresist shock. If, under dynamic conditions, copper plating is injured,the mirror will soon be ruined. If the copper begins to peel away attheedges because of improper sealing at the edges, the protectionoriginally afforded by the copper plating will soon be lost.

If the use of the mirror is such that it is essential that it be highlyresistant to shock, the mirror may be made of specially heat treatedglass. This glass is, however, expensive. The front por'- tion of theedge of a glass mirror may be beveled in order to afford some protectionto the edge in an endeavor to eliminate a frame. The beveling of glassis, however, expensive and while the mirror may be an unbeveled andunframed mirror, a

mirror which has no protection at the edges but a bevel leaves much tobe desired because of an unsanitary edge where the mirror forming filmcontacts the rear surface of the glass. Once the mirror forming filmbegins to peel because oi' the entrance of dirt between the film' andthe glass. the mirror becomes unsightly and generally unsatisfactory forthe purpose for which it was intended.

Itis an object of the instant invention to teach a novel andinexpensivemethod of fabricating a framed panel such as a'mirror withhermetically sealed edges, which will be highly resistant to shock andsanitary.

It is another object of the invention to teach a laminated frame mirrorconstruction which wllbe highly resistant to salt spray, sanitary, andresistant to shook.

It is a further object of the instant invention to teach theconstruction of a mirror with a hermetlcally sealed edge and mirrorforming film.

It is still a further object of the invention to teach the constructionof a framed shatter-proof laminated panel involving a sanitaryhermetically sealed edge.

Other objects and the nature and advantages of the invention will beapparent from the following, description taken in conjunction with theaccompanying drawing, wherein:

Figure 1 is a view in perspective of a framed mirror in accordance withthe invention showing the face of the mirror;

'Fig. la is a fragmentary detail of the corner construction of themirror shown in Fig. l;

Fig. .2 is a section taken along line 2-2 of Fig. l looking in thedirection of the arrows;

Fig. 3 is a view similarI to Figure 1 showing the rear side of theframed mirror; l

Fig. 4 is a sectional detailshowing the mirror resiliently mounted on astationary wall; and

Fig. 5 is a sectional detail of a modification.

Referring to Figures 1-4, inclusive. the mirror panel I0 is framed by anextruded plastic ll of substantially channel section, as best shown inFigure 2. The channel section comprises a base B and two legs L. Themirror panel Ill comprises a glass lamina l2, a backing lamina I3 whichmay be temperedv lignin plastic material known as Masonite to the trade,a mirror forming fllm i4 and a sealing mastic cement l5. The same masticcement l5 that extends between the mirror forming film N and the backingI3 may also extend between the inner side of the base B and 3 the edge Eof the mirror panel, between the inner side of the legs L and theexterior base of the glass and the rear side' or surface of the backingI3.

For example, -a mirror in accordance with the invention may utilize achannel frame having a 'distance between the inside of each leg L ofapproximately or slightly more and a glass lamina thickness ofapproximately 1A or slightly less. The backing thickness may beapproximately 1/8". The mirror forming film I4 may be conventional incharacter such as precipitated metallic silver. The thickness of themastic cement overlying the im I4 will, of course, be much greater indimension' than the thickness'of the mirror forming lm but it is to beof less dimension than the thicknes of the cement mastic between theedge E of the mirror panel and the v inner side of the base B of thechannel frame II, The thickness of the cementmastic between the `innerside of the legs L of the channel frame II and the mirror panel I is tob e less than the thickness of the cement mastic between the edge E andthe base B.

The screw threaded plugs I6 are chemically welded to the frame I Iwithin threaded bores Il? for the purpose later to be explained indetail.

The backing lamina I3 may be utilized to hold mounting elements to themirror panel. The two leaf springs I8, best shown in Figures 3 and el,

may each be secured to the' backing lamina t5 by two rivets R. The tworigid generally S-shaped bracket members I9 may each be secured to thebacking lamina I3 by two rivets R.. `The brackets I9 are adapted to beinserted in bracket engaging members 2l) secured to a wall W as bestshown in Fig. 4. In mounting the mirror on the wail, the mirror isplaced against the wall at a' slightly higher elevation than at whichitis to be finally mounted, the mirror is pressed against the wall soas` to impress the spring members I8, andthen the mirror is lowered sothat the brackets I9 engage the bracket engaging members as shown inFig. 4. This spring and bracket mounting has been found in practice tobe satisfactory on battleships or other naval craft having guns aboard.

In Figure 4, the attaching members are secured to the backing lamina I3by rivets, the heads of which, which are adjacent the cement mastic,directly engage the interior surface of the backing panel. When the useof the mirror` is such that great strength is to be inherent in themounting, a metal or plastic plate P may be placed over the interiorsurface of the backing lamina I3 so that the interior heads H of therivets may engage same, as shown in the modification of Fig. 5. However,when the backing lamina I3 is ofsuch material which is inherently strongin shear, the plate P may be eliminated and the construction shown inFig. 4 utilized.

In assembling the mirror shown in Fig. l, a plastic sectioncorresponding to the channel frame I I shown in Fig. 2 is extruded intolengths slightly exceeding the perimeter of the mirror. These lengths.are then cut into pieces corre sponding to the sides, top and bottom ofthe mirrorand mitered as shown in Fig l. The top portion 2l and thebottom portion 22 may be drilled and threaded as at I1. The plug lmay becut into the proper lengths from a threaded 'extrudedrodffabricated ofthe same material of which the frame Il is made.

While theframe pieces and plugs are being made, the glass lamina I2 maybe cut to size and mirrored in a conventional manner. The backing laminaI3 may also be cut to size, and the mounting members I8 and I9 rivetedthereto as already described. The mirror panel I0 may then be fabricatedby applying waterproof and preferably salt waterproof cement masticwhich may be organic in nature over either the interior surface of thebacking I3 or the exposed surface of the mirror forming film I4 or both.The unframed.

panel assembly may then be placed in the press which may be a cold or ahot press. If the glass lamina I2 is of the heat treated type, it ispreferable that a cold press be used in order not to affect the temperof the glass. Otherwise, a hot press may be used to effect the bondingbetween' the mirrored glass lamina and the backing 1amina. It has beenfound in practice that when the heat treated glass is used in connectionwith a Masonite backing and a salt waterproof organic mastic cement, acold press exerting pounds pressure to the square inch eifects asatisfactory bond.

The mitered ends M of the frame sides are then chemically treated sothat when the ends are pressed tightly together a chemical bond takesplace. The frame members are then placed about the formed laminatedmirror panel I0 within a jig to hold all the members securely in place.The bonding of the corners of the frame is then effected. Then, underhydraulic pressure, cement mastic is forced through the openings I6 inthe top portion 2| and bottom portion 22 of the frame so that cementmastic iiows between the edge E and the interior surface of the base Bof the frame II and between the panel I0 and the interior surfacesof-the legs L to form a hermeticaliy sealed edge on the panel III. Ithas been found in practice that a gun of the type used to force greaseintothe bearing elements of the d@ chassis of an automobile issatisfactory for the purpose of forcing the cement mastic between theframe II and the panel I0 as described. Because be seen by the observerlooking at the base vof the mirror, then the operator knows that theedge .of the mirror is sealed at the corresponding place of observation,so that when the mastic can be seen inthe face of and all around themirror. the mirror is completely sealed. The use of hydraulic pressureserves to effect a neat, even seal.

The mirror panel corners C may be rounded as shown in Fig. 1a in orderto insure a neat iiow about the corners for the mirror panel It).

Instead of :bonding the glass lamina I2 to the backing I3 prior to itsinsertion in the frame, they may be bonded at the same time that theframe is bonded to the panel III by utilizing a. jig or other spacingmeans which will hold the glam lamina I2 andbackingv I3 in a desired'spaced relation while the mastic is forced between 'the glass and thebacking under hydraulic pressure through the bores il. v

After the panel I 6 is formed and the frame hermeticaily sealed thereto.the plugs Il and the threaded. bores I1. are then chemicallytreatedvterial suitable for the purpose intended. For example, the framemay be of metal or wood. The frame may not only be formed by the processof extrusion but it may also be manufactured by other methods suchas bycompression molding. hand carving or it may be shaped in any suitablemanner. When the frame is made of a plastic, the edges which are to. bejoined may ybe treated with a plastic solvent Aso as to eiect a chemicalweld. When the natre of the plastic permits, heat maybe used to effectthe weld. With different types of plastics corresponding sollvents willbe used when a chemical weld is desired. The frame Joints may alsobemade with suitable cements. The plugs I8 may be connected to the boresI1 as described in connection with l the framejoints.

Though the drawing shows two bores .I'I being utilized in connectionwith the sealing of the frame II to the mirror panel I0, a single boreor more than two bores may be utilized. The bore or bores may be locatedanywhere along the frame and even at one of the mitered corners as wellas centrally at one of the sides of the frame. Though the mirror shownin the drawing is rectangular in shape, it may be ofrany geometricalshape, either polygonal, circular, elfliptical or variations thereof.Though the cement mastic which is applied between the edge E and theinside of the channel frame may be of any color, itis preferable to'have this cement mastic in a very dark color or substantially black sothat the reflection of the inner side of one of the legs L in the mirroror lack of reflection does not detract from the appearance of themirror. The frame of the mirror may be of any color which will, ofcourse, be as permanent as the plastic material utilized for theextrusion of the channel frame. It will have the qualities of theplastic and will be sanitary and durable as well as attractive. Theconstruction of the mirror is such that it is inherently shatter-proofand shockproof and in addition the reflecting qualities of the mirrorwill be permanent because of the protection afforded the mirror formingfilm by the construction described.

While the lamina I3 which forms the backing of the panel I0 has beendescribed as a tempered lignin plastic material known to the trade asMasonita it also may be made of liber or laminated `plastic resin sheetsor wood or any other suitable material. The mastic cement I5 may be -ofsuction type. or a plasticsuch as poly-vinylbutyral plastic or othersimilar plastics. It also may be a synthetic organic rubber bearing saltwater proof cement.

While the mastic cement IB may be the same between the laminae andbetween the edge E and' the inside of the frame, one typeof masticcement or adhesive maybe used between the laminaeand another typebetween the edge E and the inside of the frame.

Though the glass lamina may be of V4" thickness, a glass thickness ofVs" or less may be used because the construction described is inherentlystrong and relatively thin, light materials may be used to-advantage.

While the plugs I6 have been-described as being screw threaded, theplugs need not be threaded and may be either cylindrical or tapered in Yirustro-conical shape.

Whereas specific wall attaching means has been described in connectionwith the illustration shown in Figures 3, 4 and 5, other wall attachingmeans may be utilizedwithout depart- 6. ing from the spirit of theinvention. Not uinly may wall attaching means be associated with thebacking I3, the hinges may be secured thereto or to the frame so thatthe finished hermetically sealed panel may act as a door or cover or lidsuohas the door to a medicine cabinet, for example. The wall attachingmeans may also be made integral with one of the plugs I6.Y The plugs I6may also be extended sotthey may act as pivots in fixed supportingsockets so that the mirror can be pivotally mounted.

It will be obvious to those skilled in the art that various changes maybe made without departing from the spirit of the invention and thereforethe invention is not limited to what is shown in the drawing anddescribed in the speciflcation but only as indicated in the appendedclaims.

What is claimed is:

1. A plastic framed laminated mirror panel comprising a lamina ofmirrored glass, a lamina,

y of salt waterproof organic mastic cement, and a lamina of temperedlignin plastic material, a channel shaped plastic frame extending aboutthe edges of said laminae and a mastic cement between the inside of thechannel of said frame and the edges ci' said laminated panel.

2. The method of fabricating a plastic framed laminated panelcomprisingshaping a length of channel frame section including a base andtwo legs, holding a plurality of laminae in spaced relation, with theedges `thereof framed by the channel section but in spaced relationthereto, forcing under pressure cement mastic between the inside of thebase and the edges of the laminae and the laminae so that the laminaeare bonded together and the edges of the bonded laminae are bonded vtothe frame simultaneously.

3. The method of fabricating a plastic framed laminated panel comprisingshaping a length of channel frame section including a base and two legs,cutting said length of said frame section to a plurality of framemembers, mitering said frame members, associating said laminae with saidframe'members in a manner so as to have the edges of the laminae framedby the channel section but .held in spaced relation thereto, chemicallybonding the mitered edges of said frame members, then forcing underpressure a cement mastic between the inside of said base and the edgesof said laminae to form a framed laminated panel having hermeticallysealed edges.

4. The method of fabricating a plastic framed laminated panel comprisingshaping a length of channel frame section including a base and two legs,cutting the length of frame section into four sides, mitering the endsoi said sides, chemically bonding the mitered edges, drilling aholethrough one of the frame sides for the entrance of the cement masticunder pressure, holding a plu- I Arality of laminae so as to have theedges ofv the 5. The' method of fabricating a plastic framed' laminatedpanel comprising shaping a length of v channel frame section including abase and two legs, holding a plurality of spaced laminae'so as to havethe edges framed by the channel section but in spaced relation thereto,simultaneously bonding said laminae to each other and. the frame to theedges of said laminae by forcing under pressure a cement mastic betweenthe laminae and between the edges thereof and the frame.

6. A plastic framed laminated mirror panel comprising a lamina ofmirrored glass, a lamina of salt Waterproof organic mastic cement, anda, lamina of tempered lignin plastic material, a

frame extending about the edges of said laminae ard a mastic cementbetween the inside of said f; ame and the edges of said laminated panel.

7. The structure recited in claim 1, said chanl nel shaped plastic tramehaving a. section comprising a base and two legs, the space between theedges ofvsaid laminae and the inside o! said base being of greaterdimension than the space between the surface of said laminae adjacentthe edges thereof and the inside of said legs.

8. A hermetically sealed plastic framed laminated mirror panelcomprising a lamina of mirrored glass, a lamina o! salt-water prooforganic mastic cement, and a lamina of sheeting, a frame extending aboutthe edgesV of said laminae and l overlying the margins of the face ofsaid glass lamina and the margins of theback oi' said sheeting, and amastic cement between the inside ci! said frame and the edges of saidlaminated panel.

EPHRAIM WINEE.v

